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Blue is better

COMPRESSOR TECNOLOGY FOR THE LOW GWP REFRIGERANTS. London - 26° April 2012 RAC question time. 1. Eng. Marco Caldara Frascold R&D laboratory manager. Blue is better. Introduction. 2. Blue is better. Refrigerants. HFO R407F CO2. Current activities. Compressor design.

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Blue is better

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  1. COMPRESSOR TECNOLOGY FOR THE LOW GWP REFRIGERANTS London - 26° April 2012 RAC question time 1 Eng. Marco Caldara Frascold R&D laboratory manager Blue is better

  2. Introduction 2 Blue is better

  3. Refrigerants • HFO • R407F • CO2 Current activities Compressor design • Design evaluation for drop-in allowance • Design evolution for performance increasing • Application envelope extensions Validating application • Suggest refrigerant choice • Hybrid system • Field test in different location for seasonal TEWI calculation purposes 3 Blue is better

  4. R&D case study R1234ze TESTING EXPERIENCE 4 Blue is better

  5. Summary • Testing routine instruction • Testing equipment and methods • Refrigerant properties databases • Results • Operations • Current state of test program • Design evolution • Selection software update 5 Blue is better

  6. Testing routine instruction TEST PLAN Measure compressor parts Assembling compressor Tightness test Oil charge Installing on test rig and evacuate for 12 h Test and record time + working condition Recover refrigerant and uninstall from test rig Taking oil sample for analysis Dismantle compressor Measure compressor part (500 h). 6 Each test result contributes to the entire project final result Blue is better

  7. Test equipment and methods TEST RIG: 300kW 7 Blue is better

  8. Test equipment and methods TEST RIG: 300kW • Built by ILK Dresden in 2004. • Test according to EN13771-1 • Two Coriolis mass flow meter • LP side, method D1 • HP side, method D2 • Oil separator • Power supply from stabilized grid • Four independent PID controllers • Pressure measurement uncertainty lower than 1% • Temperature measurement uncertainty lower than 0,3 K • Power measurement uncertainty lower than 1% • Water cooled condenser and subcooler • Performance uncertainty lower than 5% 8 Blue is better

  9. Test equipment and methods PERFORMANCE DATA PROCESSING STEP Placing testing point Expect limits Break-in time (24 h) Reproduce conditions Go outside limits Check results Use interpolation software Evaluate efficiency curve Create performance model 9 Blue is better

  10. Refrigerant databases REFRIGERANT PROPERTIES DATABASE: • NIST refprop 9.0 • ILK REFLIB for MS Excel 2.1 10 Blue is better

  11. Results – key points • Compressor performance • Performance test • Numeric simulation • Refrigerant comparison • Oil behavior • Compressor parts wearing 11 Blue is better

  12. Results – performance test 12 Blue is better

  13. Results – Numeric simulation 13 Blue is better

  14. Results – Refrigerant Comparison 14 Blue is better

  15. Results – Oil behavior EVALUATED OIL: • POE 68 cst • PAG 68 cst • POE 170 cst (screw) • POE 68 cst Oil level was regulated at half of the sight glass on compressor crankcase by an optical level switch. • LUBRICATION AT COLD START UP • SUDDEN PRESSURE DECREASE (FOAM) • FORCED LUBRICATION – PUMP DIFFERENTIAL PRESSURE • GAS TRAPPING WHEN DISCARDED 15 Blue is better

  16. Results – compressor parts wearing EVALUATED COMPONENTS: • PISTON AND PISTON RINGS • SHAFT • RODS • BUSHES • VALVE PLATE REEDS • LIGHT WEARING (NORMAL) • NO OVERHEATING SIGN ON VALVE REEDS AND ROTATING PARTS • ABSENCE OF DIRT OR PARTICLES 16 Blue is better

  17. Operations NEEDING ADDITIONAL CARE FOR: • LOADING – UNLOADING OF THE REFRIGERANT • FLAMMABILITY ISSUE: VENTILATION OF AREA • STOCK AND HANDLING • VACUUM OPERATION ? • No difference in loading operation, but lower pressure at given temperature • Same ambient condition • Same stock area and procedure • Additional vacuum time to sample oil after test 17 Blue is better

  18. Test program • 1° step: drop in of refrigerant in standard model • 2° step: Evaluated R134a model range • 3° step: HFO dedicated model to enhance favorable behavior • 4° step: field test running and confirmation test • 99% compatible with standard model (dedicated oil) • different performances requires technology adaption 18 Blue is better

  19. Design evolution • Motor optimized for HFO • New valve plate • Reduced clearances • Optimizedbore-strokeratio 19 Blue is better

  20. Design evolution • Different motor size tested to catch higher efficiency • different bore-stroke solutions will be evaluated in future. • New design of valve plate under evaluation • Thanks to lower power consumption motor efficiency improvement is possible and necessary • Shorter stroke compression helps with low density refrigerant in suction stage • Valve plate for higher specific volume 20 Blue is better

  21. Selection software update • Refrigerant model available • Compressor efficiencies available for tested models • Other models could be calculated having tested performaces with HFC and conversion tools • Models need confirmation test on oher sizes • Thanks to similarity with R134a conversion is plausible and tested to define accuracy • Performance calculation in progress. 21 Blue is better

  22. Thanks ! COMPRESSOR TECNOLOGY FOR THE LOW GWP REFRIGERANTS QUESTIONS? 22 Blue is better

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